Privacy curtain on a roll

ABSTRACT

An assembly and method for forming a cubicle curtain includes providing a curtain assembly with a curtain-supporting dispenser core supporting a curtain material. The curtain material has a length, a width, an upper connector portion spanning substantially the entire width, a mesh portion spanning substantially the entire width, a lower portion spanning substantially the entire width and coupled to a lower edge of the mesh portion, a horizontal line of weakness spanning substantially the entire width, and at least one vertical line of weakness spanning substantially the entire length. A first portion of the curtain material is unrolled from the dispenser core so that at least one of the at least one vertical lines of weakness is exposed and a force sufficient to separate the first portion of the curtain material from the dispenser core is applied to the vertical line of weakness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) based on U.S. Provisional Patent Application Ser. No. 61/394,492, filed Oct. 19, 2010, the contents of which are relied upon and incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to privacy curtains and, more particularly, relates to single-piece privacy curtains for health-care facilities and other applications where the curtain is provided on and dispensed at the facility directly from a roll.

BACKGROUND OF THE INVENTION

Privacy curtains, or “cubicle curtains,” are well known and are used to divide areas and/or provide privacy in healthcare facilities, such as hospitals, nursing homes, and other applications. Virtually every fire code requires the upper section of every cubicle curtain to be made of a mesh material, called the “top mesh.” in the event of a fire, the top mesh allows water from ceiling sprinkler heads to pass through the patient privacy curtain and extinguish objects on the other side of the curtain that may be on fire. Curtains having this mesh are referred to as “top-mesh curtains.” The lower section of these curtains, which is generally sewn to the bottom of the mesh section, is usually a solid piece of opaque material that provides visual privacy.

Cubicle curtains are manually hung on carriers (hooks) that slide through or along a channel or I-beam track that is permanently attached flush with the ceiling. In the majority of hospital/patient care facilities, the ceilings are eight to nine feet from floor to ceiling, which makes it impossible for a facility's maintenance/engineering/environmental services personnel to reach the carriers and hang the curtains without using a ladder or other elevating tool. Use of a ladder or lift is necessary at the time of the initial installation of the curtains, and also every time the curtains are removed for cleaning and/or repair.

Depending on individual facility policy, cleaning may be done as oaten as weekly or whenever a patient is discharged or moved to another area of the facility. Hospital infection control standards require that if any portion of the top-mesh curtains are stained as a result of human or chemical fluids, they must be taken down and cleaned using prescribed cleaning methods to remove all contaminants. When a small area of the curtain is stained, the entire curtain with its top mesh must be removed and transported to a cleaning facility. Patient privacy regulations mandated by Health Insurance Portability and Accountability Act (HIPP A) require that a replacement curtain be hung in patient bed areas and/or patient treatment areas when such a curtain is sent for cleaning.

Cleaning of top-mesh curtains is either done in the facility's in-house laundry, using large capacity industrial cleaning machines, or by a contracted outsourced cleaning service that comes to the facility, removes the soiled curtains (using a ladder or lift), hangs temporary replacement top mesh curtains (also using a ladder or lift) and takes the facility's soiled curtains to a laundry for cleaning. The facility is charged both for the service and for the use of leased temporary curtains, in each case, the task of removing and replacing top-mesh curtains is titne-consuming and the cost in manpower and required equipment is extensive.

Currently there are sixteen industry-standard widths, span from 72″ to 360. As a result of the different sizes, the hospital/care facility is required to carry additional spare topmesh curtains as laundry replacements so that the facility is able to have continuous utilization of hospital beds and/or treatment areas.

The housekeeping staff/cleaning service is also required to hang the correct curtain onto the proper sized track, with respect to the track's horizontal length. The curtain is usually 10-20% larger than the track that it is made for to assure proper patient privacy. Searching through the various curtains stored in the laundry area to find the appropriately sized curtain is an inefficient use of manpower. It is very time consuming for the staff responsible for re-hanging curtains, and expensive for the facility, as staff could be performing other necessary tasks. Also, the curtains are routinely hung on improper track sizes, resulting in inadequate patient privacy.

Because there is no standard size for prior-art curtains, during manufacturing, the sewing room staff must manufacture each curtain to exact specifications, changing cutting and sewing measurements for each order. A large expense results from having to fulfill these custom orders.

In addition, when manufacturing prior-art curtains to the industry standard, a sewing room needs three different types of sewing machines before sending the cubicle curtain off to be grommetted: (1) a surge type sewing machine; (2) a ½″ double needle sewing machine; and (3) a ¼″ double needle sewing machine. The purchase and maintenance of these three machines is costly. In addition, movement of each curtain from one machine to the next is labor intensive and, therefore, increases labor costs and the possibility for defective workmanship.

Therefore, a need exists to overcome the problems with the prior art top-mesh curtains as discussed above.

SUMMARY OF THE INVENTION

The invention provides a privacy curtain on a roll that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that is quickly and conveniently made to the desired size on site and on demand.

Briefly, in accordance with the present invention, disclosed is a curtain assembly and method of installing a curtain assembly comprising a single piece of material provided, preferably, on a roll, where the material includes a mesh section, a solid privacy section, and perforations for cutting/tearing panels to the desired size.

Although the invention is illustrated and described herein as embodied in a privacy curtain provided on a roll, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.

With the foregoing and other objects in view, there is provided, in accordance with the invention, an assembly and method for forming a cubicle curtain that includes providing a curtain assembly that features a curtain-supporting dispenser core surrounded by and supporting a curtain material. The curtain material has a length, a width, an upper connector portion spanning substantially the entire width, a mesh portion spanning substantially the entire width and coupled to a lower edge of the upper connector portion, a lower portion spanning substantially the entire width, coupled to a lower edge of the mesh portion, and having a horizontal line of weakness spanning substantially the entire width, and at least one vertical line of weakness spanning substantially the entire length. The method includes unrolling a first portion of the curtain material from the dispenser core so that at least one of the at least one vertical lines of weakness is exposed, applying a force to the exposed at least one vertical lines of weakness, the force sufficient to separate the first portion of the curtain material from the dispenser core, and coupling the separated first portion of the curtain material to a curtain track coupled to a ceiling.

In accordance with a further feature of the present invention, the at least one vertical line of weakness has a tear force less than a tear force of portions of the curtain material immediately on either side of the at least one vertical line of weakness.

In accordance with another feature of the present invention, at least one of the at least one vertical lines of weakness and the horizontal line of weakness comprises a perforated line.

In accordance with yet another feature of the present invention, the curtain material is of a homogenous material. In other words, the entire curtain assembly is formed from a single piece of fabric/material which, in accordance with one embodiment, is a nonwoven material and is formed by a die cutting process for form the apertures therein.

In accordance with a further feature of the present invention, prior to step of coupling the separated first portion of the curtain material to a curtain track coupled to a ceiling, a force is applied to the horizontal line of weakness of the separated first portion of the curtain material, where the force is sufficient to separate the lower portion of the first portion of the curtain material into two separate pieces.

In accordance with another feature, an embodiment of the present invention includes a curtain assembly has a curtain material with a length, a width, art upper connector portion spanning substantially the entire width and having apertures sized and spaced to mate with carriers of a ceiling curtain track, a lower portion coupled to the upper connector portion, although not necessarily directly, and spanning substantially the entire width and at least one vertical line of weakness spanning substantially the entire length, the at least one vertical line of weakness having a tear force less than a tear force of portions of the curtain material immediately on either side of the at least one vertical line of weakness.

Other features that are considered as characteristic for the invention are set forth in the appended claims. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the teens and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.

Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.

As used herein, the terms “about,” “approximately,” and/or “substantially” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. In this document, the term “longitudinal” should be understood to mean in a direction corresponding to an elongated direction of the supporting roll core.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.

FIG. 1 is a fragmentary side elevational view of a curtain assembly in accordance with an exemplary embodiment of the present invention;

FIG. 2 is a side elevational view of an exemplary embodiment of a curtain assembly provided on a roll dispenser in accordance with an exemplary embodiment of the present invention;

FIG. 3 is a process flow diagram illustrating an exemplary process for forming a cubicle curtain of a desired size; and

FIG. 4 is a partial close-up view of the upper connector and mesh portions of the curtain of FIG. 1, showing alternate aperture shapes and arrangements in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention.

The present invention, according to an embodiment, overcomes problems with the prior art by providing a continuous sheet of privacy curtains on a roil-type dispenser, where individual curtains are removable in panels of standardized size by cutting or tearing along predefined lines, e.g. perforations, resulting in a curtain inventory that is easily and conveniently stored and individual curtain dimensions are determined on-site. The curtains have a light panel weight that is easy to install and carry, and include an attachment mechanism for securing the curtains to ceiling track hooks. The inventive privacy curtain also provides significant manufacturing advantages over the prior art that results in lowered manufacturing cost and better yield.

Described now are exemplary embodiments of the present invention. Specifically, with reference to the drawings, FIG. 1 shows a one-piece privacy curtain assembly 100 that is provided in a length “G” and, as will be described below, a variable width “F.”

The inventive curtain assembly 100 includes, as a first section, an upper connector portion “B” that that couples the privacy curtain assembly 100 to a flush-mounted track on a ceiling (not shown). Flush-mounted tracks and hooks for connecting cubicle curtains to tracks are well-known in the art. The upper connector portion “B” features apertures “J” that are spaced a distance “A” from each other. In one embodiment, the apertures “J” are one-inch diameter circular openings that are each placed about six inches on center across the entire horizontal width “F” of fabric.

As is known in the art, a flush-mounted track on a ceiling is an elongated channel that allows sliders to slide along the length thereof. By mechanically coupling the sliders to the upper connector portion “B” and, in particular, the apertures “J” of the curtain assembly 100, the curtain assembly 100 can easily be physically displaced along the track. The curtain assembly 100 can be slid in one direction along the track to stretch the curtain assembly 100 and form a “wall,” thereby blocking an interior of an area from view from outside thereof. Alternatively, the curtain assembly 100 can be slid in a second direction, bunch up upon itself, and compress into a small area. In this configuration, the curtain acts as a portable foldable wall. It should be noted that the present invention is not limited to any particular type of track or sliders. In embodiments of the present invention, the apertures “J” are provided with strengthening members, such as grommets, eyelets, loops, snaps, fasteners, or any other measures for attaching the curtain assembly 100 to a ceiling track.

Next, coupled to the upper connector portion “B,” and starting about two inches from the top of the panel's fabric selvedge, is a mesh portion “C”. The mesh portion features a plurality of apertures “K” and is, in accordance with one embodiment, about 20 inches in length, but the invention is not so limited. Length, as used herein, will refer to the direction indicated by reference letter “G” in FIG. 1. In accordance with one embodiment of the present invention, the plurality of apertures “K” creates an open-weave design allowing for about a 75% openness factor. Virtually every set of municipal fire codes requires the upper area of such top-mesh curtains to be made of a material that will allow water from ceiling-mounted sprinkler heads to pass therethrough. This feature allows water from the sprinkler heads, no matter where the curtains are hung in relation to a sprinkler head, to be able to reach a person or an object on the other side of the curtain in the event of an emergency. The roughly 20 inch length of the aperture mesh section is sufficiently large to allow water to penetrate through the curtain and meets or exceeds most guidelines set forth by the National Fire Protection Association for such vertical mesh. The present invention, however, is not limited to mesh top panels and can be provided in any other material when used for purposes that are not controlled or regulated by fire codes that require such mesh.

Below and coupled to portion “C” of the curtain assembly 100 are portions “D” and “E.” Portions “D” and “E” are, at least initially, coupled to each other to form a continuous piece of material. However, advantageously, a line “H” is provided between the portions “D” and “E” that allow portion “E” to be separated from portion “D.” The line “H” is a line of weakness or simply a guideline that can be cut. A “line of weakness,” as used herein, is intended to indicate a line of weakened material, for example, a perforated line. Regardless, the line “H” allows the curtain to be quickly and easily reduced in size from its original provided dimension. In accordance with one embodiment, portion “D” has a length of about 62 inches, measured between the line “H” and the center of the lowest row of apertures “K” in section “C,” but the invention is in no way limited to such a dimension.

Section “E” has a length of about 12 inches from line “H” to the bottom selvedge edge of the fabric panel assembly 100, however the invention is in no way limited to such a dimension. Advantageously, due to the presence of line “H,” the inventive panel assembly 100 is instantly convertible between two standard curtain heights. That is, as shown in FIG. 1, the curtain assembly 100, with portions “D” and “E” attached to one another, is about 96 inches in vertical length (dimension “G”). By removing portion “E,” which is easily accomplished by the presence of line “H,” the panel assembly is quickly reduced to about 84 inches in vertical length (particularly useful for applications where the ceiling height is only 8 feet).

In accordance with embodiments of the present invention, the entire width “F” of the assembly 100 is about 50 to 100 yards of continuous material. The assembly 100 is provided with a second line “I” that is vertically oriented. As with line “H,” line “I” is, preferably, a perforated line, which allows the continuous roll of curtain material to be separated into panels of predefined widths. For instance, the lines “I” can appear every about 72 inches. Of course, the invention is not so limited and other dimensions are feasible as well.

The entire panel assembly 100, including the mesh portion “C” is, in accordance with one embodiment of the present invention, of a single material. The term “single material,” as used herein, indicates a homogenous or relatively homogeneous material. Advantageously, the inventive curtain assembly 100 can be made of a single-piece non-woven polyester fabric. The non-woven polyester (pulp) can be rolled out in large sheeting runs and the design forming top-mesh and holes are stamped out with, for example, a cookie-cutter-type die. No additional labor is required to finish the curtain, which is then placed on a roll and is ready for delivery to the end user.

As one example of a material, the entire panel assembly 100 can be made from a single piece of polypropylene. Advantageously, polypropylene is inexpensive and, once used, can economically be thrown away and simply replaced rather than cleaned. This alleviates the expense and issues associated with cleaning the curtains, as well as realizes a large reduction in infections associated with bringing contaminated curtains in contact with other curtains and washing devices. Alternatively, the curtains can be recycled, especially since they are made of a single (homogeneous) material.

Advantageously, the inventive curtain assembly 100 can be from many alternate materials other than or in addition to polypropylene. A preferred material is one that removes from the ceiling tracks simply by applying sufficient force to tear the upper apertures “J”.

Aesthetics can be significantly enhanced by including a decorative pattern on part or all of the material forming the curtain assembly 100. In accordance with one embodiment, a “paper” pattern/design can be used to print on the fabric material, which can be non-woven fabric material. The printing can be accomplished through “heat-setting” the pattern on the non-woven fabric material similar to the way transfer-printing is placed on tee-shirts.

In yet another embodiment of the present invention, the material is a visible-light black-out material that eliminates or attenuates light from entering the area behind the curtain 100. Additionally, the curtain can be made of a flameproof or flame-resistant material. Furthermore, the curtain can be of a waterproof material that prevents fluids from being expelled from within a cubical.

FIG. 2 shows the inventive curtain assembly 100 disposed around a roll core 200. The roll core 200 can be similar to a roll core commonly found supporting rolls of carpet. In accordance with one embodiment, each roll of unprocessed material is about 250 yards long and is approximately 0.015″ thick. On a core 200 having an exemplary 3″ diameter, the overall material roll diameter would be about 14″. The roll core 200 can be secured within a rack or other holding device and allows sections (lengths) of a desired length of the curtain assembly 100 to be easily removed.

FIG. 4 provides a close-up partial view of the upper connector portion “B” with apertures and an alternative shape configuration of the mesh portion “C” forming apertures “K”. In the embodiment shown, the mesh portion “C” includes a die cut pattern forming a series of staggered rounded rectangles “K” in a repeating grid pattern. The pattern can form a break 402, e.g., two inches wide, in the pattern repeated at a distance 404, e.g., every 24″, to allow for cutoff of the material by the end user. The exemplary pattern may also include a perforation centered in the two inch pattern break to ease cutting/separating the finished product by the end user.

FIG. 3 is a process flow diagram illustrating an exemplary process for forming a cubicle curtain of a desired size. The process begins at step 300 and moves directly to step 302 where the above-described continuous roll of curtain material, shown in FIGS. 1 and 2, is provided to a user.

In step 304, a first portion of the curtain material is unrolled from the dispenser core so that it separates away from the core, although still attached to the rest of the roll of material, and at least one of the at least one vertical lines of weakness is exposed. The exposed line can be the first line encountered or can be one that is several roll layers deep toward the core and requires extensive unrolling of the curtain material from the core.

In step 306, a force is applied to the exposed vertical lines of weakness sufficient to separate a first portion of the curtain material from the dispenser core. In step 308, a decision is made as to whether or not the removed section of material is of the correct length for the desired application. If the answer is yes, the process moves to step 310 where the separated first portion of the curtain material is mechanically coupled to a curtain track attached to a ceiling. If the answer to step 308 is no, the process moves to step 312 where a force is applied to the horizontal line of weakness of the separated first portion of the curtain material so that the lower portion of the first portion of the curtain material into two separate pieces and the overall length is reduces. The flow then moves to step 310.

In step 314 a decision is made as to whether or not further curtains are necessary. If the answer is yes, the process moves back up to step 304. If the answer is no, the process ends at step 316.

A single-piece curtain has just been described that includes a continuous roll of curtain material with features that allowing quick and easy sizing of the material to a desired length/width. Advantageously, the sizing is performed on-site and on-demand and the material can then be easily hung and/or removed from a ceiling track as needed. The inventive curtains can be easily disposed of when desired and replaced. The present invention is an improvement over the prior art not onl in the enhanced safety when changing the panels, but in cost for inventory, laundry, handling, manufacturing, material, and in some applications, containment of infections.

Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover arty and all such applications, modifications, and embodiments within the scope of the present invention. 

1. A curtain assembly comprising: a curtain material having: a length; a width; an upper connector portion spanning substantially the entire width and having apertures sized and spaced to mate with carriers of a ceiling curtain track; a lower portion coupled to the upper connector portion and spanning substantially the entire width; and at least one vertical line of weakness spanning substantially the entire length, the at least one vertical line of weakness having a tear force less than a tear force of portions of the curtain material immediately on either side of the at least one vertical line of weakness.
 2. The curtain assembly according to claim 1, further comprising: a curtain-supporting dispenser core surrounded by and supporting the curtain material.
 3. The curtain assembly according to claim 1, further comprising: a mesh portion spanning substantially the entire width and coupled to a lower edge of the upper connector portion and an upper edge of the lower portion.
 4. The curtain assembly according to claim 1, further comprising: a horizontal line of weakness spanning substantially the entire width.
 5. The curtain assembly according to claim 4, wherein: at least one of the at least one vertical line of weakness and the horizontal line of weakness comprises a perforated line.
 6. The curtain assembly according to claim 1, wherein the curtain material comprises: a homogenous material.
 7. The curtain assembly according to claim 1, wherein the curtain material comprises: polypropylene.
 8. The curtain assembly according to claim 1, wherein: the length is approximately 96 inches.
 9. A curtain assembly comprising: a curtain-supporting dispenser core; and a curtain material supported by the dispenser core, the curtain materia having: a length; a width; an upper connector portion spanning substantially the entire width; a mesh portion spanning substantially the entire width and coupled to a lower edge of the upper connector portion; a lower portion spanning substantially the entire width, coupled to a lower edge of the mesh portion, and having a horizontal line of weakness spanning substantially the entire width; and at least one vertical line of weakness spanning substantially the entire length.
 10. The curtain assembly according to claim 9, wherein: the at least one vertical line of weakness has a tear force less than a tear force of portions of the curtain material immediately on either side of the at least one vertical line of weakness.
 11. The curtain assembly according to claim 9, wherein: at least one of the at least one vertical lines of weakness and the horizontal line of weakness comprises a perforated line.
 12. The curtain assembly according to claim 9, wherein: the curtain material is a homogenous material.
 13. The curtain assembly according to claim 9, wherein the curtain material comprises: polypropylene.
 14. The curtain assembly according to claim 9, wherein: the length is approximately 96 inches.
 15. A method for forming a cubicle curtain, the method comprising: providing a curtain assembly that includes: a curtain-supporting dispenser core; and a curtain material supported by the dispenser core, the curtain material having: a length; a width; an upper connector portion spanning substantially the entire width; a mesh portion spanning substantially the entire width and coupled to a lower edge of the upper connector portion; a lower portion spanning substantially the entire width, coupled to a lower edge of the mesh portion, and having a horizontal line of weakness spanning substantially the entire width; and at least one vertical weakness spanning substantially the entire length; unrolling a first portion of the curtain material from the dispenser core so that at least one of the at least one vertical lines of weakness is exposed; applying a force to the exposed at least one vertical lines of weakness, the force sufficient to separate the first portion of the curtain material from the dispenser core; and coupling the separated first portion of the curtain material to a curtain track coupled to a ceiling.
 16. The method according to claim 15, further comprising: prior to the coupling step, applying a force to the horizontal line of weakness of the separated first portion of the curtain material, the force sufficient to separate the lower portion of the first portion of the curtain material into two separate pieces.
 17. The method according to claim 15, wherein: the at least one vertical line of weakness has a tear force less than a tear force of portions of the curtain material immediately on either side of the at least one vertical line of weakness.
 18. The method according to claim 15, wherein: at least one of the at least one vertical line of weakness and the horizontal line of weakness comprises a perforated line.
 19. The method according to claim 15, further comprising: unrolling a second portion of the curtain material from the dispenser core so at least one of the at least one vertical lines of weakness is exposed; and applying a force to the exposed at least one vertical line of weakness, the force sufficient to separate the second portion of the curtain material from the dispenser core.
 20. The method according to claim 15, wherein the curtain material comprises: a homogenous material. 